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Replacing hoses and regulator on gas grill

Have a Kenmore gas grill (415.162140) that I purchased in '04. Used it regularly, but not exactly frequently (it took me 3 years to go thru 1 tank of propane). Worked great until last summer when my local woodland creatures chewed a hole in the gas line leading to the side burner.
The replacement part for the valve and regulator assembly, which includes the hoses (part #4524195) has been discontinued. No replacement or alternate part has been specified by Kenmore that I can find. No standardized replacement regulators and hoses that I've seen in the stores look useful, since the hoses on the Kenmore part are permanantly clamped onto the regular and valves instead of screwed on.
So my question is - is there anything I can do to fix this grill, or is it toast? I considered duct tape, but figured it wasn't safe. (just kidding!) Thanks.

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  • Kenmore Master
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I work for a propane co. I get many customers that bring in their melted or leaking bbq grill hoses and regs. Bring the bad hose/reg to your local propane gas co and see if they can make a custom hose for you. You may have to buy a new regulator to use it with the new hose, but that's better than buying a new grill. Call around first and see which ones can do it. You'll eventually find someone that can fix you up.

Posted on May 16, 2010

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1 Answer

I have a Kenmore model 141.16681 and gas now leaks at the regulator valve


check regulator to see that the rubber seal in the tank coupling
is still good if this has perished or fallen out this maybe the cause of
gas at this point.
best purchase a new regulator if it seems faulty, this part is your life saver, and after 8 years good service could well need replacement.

I hope this was useful.

Sep 01, 2012 | Kenmore Elite 644 sq. in. Cooking Area Gas...

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I would like to convert a grill that was used on natural gas back to propane. Can I just purchase a regulator and hose and be good, or do I need to change anything else on the grill?


Burner orifices must be resized or adjusted to accommodate higher pressure LP.
Air shutters should be opened all the way to allow maximum air to gas ration.

Sep 14, 2011 | Barbeques Galore Capt'n Cook 3-Burner...

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I purchased a used Masterbuilt veranda gas grill. The gas regulator fits a small propane tank. Is it possible to replace the regulator so it will fit a large sized propane tank?


Yes, it can be converted to accept a 20 Lb LP grill tan. Contact Masterbuilt Customer Service
1.800.489.1581 to obtain the new hose/regulator assembly.

Hope this helped you and Happy Grilling!

Jul 22, 2011 | Masterbuilt SBMPG3 Veranda Steel Grill

1 Answer

My first 2 burners furthest from the tank light alright, however when I light the middle burner or the other 2 closest to the tank my flame dies out.


Sean, It sounds like a gas pressure problem, that may be easy to resolve.

1. Turn the gas tank valve OFF

2. Disconnect the hose from the tank and wait five minutes.

3. After 5 minutes, reconnect the hose to the tank and open the tank valve VERY, VERY SLOWLY
(Slow Motion, slow).

4. Once the valve is fully open, light the burner farthest from the tank first and turn it to HIGH. Does the
Flame height look correct? If so, light the remaining burners the exact same way. Now, did all
the remaining burners light and the flame heights look normal? If so, you solved the problem.
Remember, always turn the tank valve ON Very, Very Slowly.

If that did not solve the problem, you will need to replace the grill's Hose/Regulator assembly. You can purchase one for about $30,00 from any home improvement center or hardware store that sells gas grills and accessories. Take your old one with you for comparison purposes.

Hope the helped you troubleshoot and solve the problem. Please let me know and Happy Grilling!!

Jun 18, 2011 | Kenmore 882 sq. in. Cooking Area Gas Grill...

1 Answer

The knob on the gas regulator cracked off and we are not able to get it off. Is there a special tool to get the regulator off, if not how do you replace the whole regulator and hose combination. There is...


Short of carefully using a pipe wrench, there's not much else you can do. Make sure the tank valve is fully OFF, before attempting removal. Once it's disconnected, you will need to purchase a new Hose/Regulator Assembly. They are not expensive and can be purchased at any home center or hardware store that sells gas grills and accessories. Take the old one with you for comparison purposes.

Hope this helped you and Happy Grilling!!

May 24, 2011 | Ducane Meridian 30557501 Propane Grill

1 Answer

How to i take off my regulator on my blue ember bbq. FG50069 model clockwise or counter ?


The regulator is part of the Regulator/Hose Assembly. You won't be able to separate the regulator from the hose. You have to remove the whole assembly by turning the coupling connection at the grill head counterclockwise. I assume you won't to replace the regulator. If that's the case, you will have to purchase the whole regulator/hose assembly.They are not expensive and can be found at any home center or hardware store that sells gas grills and accessories. Take your old one with you for comparison.

Hope this helped you and Happy Grilling!!

Apr 21, 2011 | Fiesta Blue Ember Gas Grill

1 Answer

Gas is barely flowing-used to hear hiss before I lit. Tried replacing pressure valve and got a new tank of gas. Also disassembled manifold and cleaned out all burners.


I had the same problem years ago with an old charbroil and ended up fixing by replacing the threaded female gas connector on the regulator with one of the old style male inside threaded type. This is the connector that connects the hose/regulator to the propane tank.

Aug 20, 2010 | Weber Genesis Silver C Grill

1 Answer

The burners are not burning properly. The gas line seems to be clogged. Do you have any troubleshooting suggestions?


Replace the hose and regulator if this is an LP grill...... or just the regulator if this is a NG grill.

Jul 03, 2010 | Kenmore 700 sq. in. Cooking Area Gas Grill...

1 Answer

Heat is about low or just a little higher on high setting


Low flame, low temperature, yellow flame: This has become the biggest problem with many grills these days and it's almost always because of the regulator (the funny UFO shaped thing on the gas hose). Regulators seem to be stickier these days and when they stick you don't get enough gas to generate a good grilling temperature. To get your regulator unstuck you need to release the pressure on it. Follow these steps exactly:
  1. Turn off the gas at the propane tank
  2. Disconnect the gas line from the tank
  3. Open the grill lid
  4. Turn all control valves to high
  5. Wait for about a minute
  6. Turn all control valves to off
  7. Reconnect the gas line to the tank
  8. SLOWLY turn on the gas at the tank
  9. Light the grill normally
  10. Your grill should now heat normally
To keep the regulator from sticking again make sure that you turn off the control valves first, then turn off the tank valve. Always open your tank valve slowly. If this doesn't work give it a second try. If you still have low flame then you probably have a faulty regulator that will need to be replaced.

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